Suction breast roll former and method, with flexible headbox roof

A suction breast roll former comprising:

• a) a suction breast roll having a support surface with apertures therein that are operatively connected to a vacuum source;
• b) a headbox positioned in a close proximity to said suction breast roll and adapted to supply an aqueous suspension of papermaking fibers to said support surface, said headbox including a slice body and an apron that define a slice opening therebetween, said headbox further including a flexible roof extending from said slice opening and spaced from said support surface to define a forming zone therebetween, said headbox structured and arranged to permit said flexible roof to bend over a range of movement relative to said support surface to match the shape of a drainage curve;
• and
• c) a restraining member spaced from said flexible roof and positioned to limit the range of movement of said flexible roof.

A method of forming a paper web, comprising the steps of:

• a) supplying an aqueous suspension of papermaking fibers to a forming zone created between a suction breast roll and a headbox, said suction breast roll having a support surface with apertures formed therein that are operatively connected to a vacuum source, said headbox including a slice body and an apron that define a slice opening therebetween, said headbox further including a flexible roof extending from said slice opening and spaced from said support surface to define a forming zone therebetween;
• b) passing a forming fabric through said forming zone to receive said aqueous suspension of papermaking fibers;
• and
• c) permitting said flexible roof to bend over a range of movement relative to said support surface to match the shape of a drainage curve, said headbox further including a restraining member spaced from said flexible roof and positioned to limit the range of movement of said flexible roof.